Automatic welding device for aluminum alloy powder tank car reinforcing ring group

Abstract

This invention relates to an automatic welding device for reinforcing ring assemblies in aluminum alloy powder tank trucks. The device includes a welding station with symmetrically arranged clamping support stations on both sides. Each clamping support station includes a clamping unit and a support unit installed in the center of the clamping unit. The support unit includes a driven end roller frame mechanism and a driving end roller frame mechanism. The clamping unit includes reinforcing ring clamping mechanisms symmetrically arranged on both sides of the tank assembly. By setting up the reinforcing ring clamping mechanisms, roller frame mechanisms, and welding stations, the automatic welding device can automatically complete the welding of the reinforcing rings. The working cycle is compact, and the welding time is short, thereby effectively improving production efficiency and reducing manual labor intensity.

Description

Technical Field

[0001] This invention relates to the field of aluminum alloy powder tanker manufacturing technology, and in particular to an automatic welding device for assembling reinforcing rings for aluminum alloy powder tankers. Background Technology

[0002] The tank body of the aluminum alloy powder tanker truck consists of two symmetrical tank body sub-assemblies. Each tank body sub-assembly comprises a head, an upper cylinder section, and a lower cylinder section. To ensure the strength and stability of the aluminum alloy powder tanker truck tank body, a set of reinforcing rings needs to be welded inside the tank body.

[0003] In existing technologies, the installation of reinforcing rings relies entirely on manual labor. The reinforcing rings are manually fixed to the corresponding positions on the inner wall of the tank assembly, followed by full welding using a handheld welding torch. This method is cumbersome, complex, labor-intensive, time-consuming, and inefficient. Therefore, replacing manual labor with automated production equipment is an inevitable trend. Summary of the Invention

[0004] In response to the shortcomings of the existing production technology, the applicant provides a reasonably structured automatic welding device for assembling reinforcing rings in aluminum alloy powder tank trucks. By setting up a reinforcing ring clamping mechanism, a roller frame mechanism, and a welding station, the automatic welding device can automatically complete the welding of the reinforcing rings. The working cycle is compact and the welding time is short, thereby effectively improving production efficiency and reducing manual labor intensity.

[0005] The technical solution adopted in this invention is as follows:

[0006] An automatic welding device for reinforcing ring assembly of aluminum alloy powder tank truck includes a welding station, on both sides of which are symmetrically arranged clamping support stations. Each clamping support station includes a clamping unit and a support unit installed in the middle of the clamping unit.

[0007] The support unit includes a driven end roller frame mechanism and an active end roller frame mechanism. The tops of the driven end roller frame mechanism and the active end roller frame mechanism simultaneously support the tank sub-assembly. The active end roller frame mechanism is equipped with a lifting motor and a roller drive motor. The lifting motor drives the active end roller frame mechanism to move vertically upward or downward in a straight line to level with the tank sub-assembly. The roller drive motor drives the active end roller frame mechanism to rotate the tank sub-assembly.

[0008] The clamping unit includes reinforcing ring clamping mechanisms symmetrically arranged on both sides of the tank sub-assembly. When the welding station is working, the two reinforcing ring clamping mechanisms simultaneously hold the outer side wall of the tank sub-assembly, thereby correcting the shape of the tank sub-assembly.

[0009] The structure of the welding station is as follows: it includes a base, on which a rotary motor is fixed, the output end of the rotary motor is connected to a rotary gear, the rotary gear meshes with the inner ring of a rotary bearing, the top of the base is installed with an L-shaped rotary connecting seat through the rotary bearing, and the rotary motor drives the rotary connecting seat to rotate through the rotary bearing.

[0010] A transverse arm is fitted to the top of the vertical section of the rotating connecting seat. A robotic arm is fitted to one end of the transverse arm, and a welding torch is fitted to the working end of the robotic arm. A transverse rack is fitted to one side of the transverse arm, and several parallel transverse slide rails are fitted to the bottom of the transverse arm. Each transverse slide rail is fitted with several transverse sliders, which are installed at the top of the vertical section of the rotating connecting seat. A transverse motor is fixed on the vertical section of the rotating connecting seat. The output end of the transverse motor is connected to a transverse gear, which meshes with the transverse rack. The transverse motor drives the transverse arm to reciprocate linearly along the transverse slide rails through the transverse gear and the transverse rack, thereby driving the robotic arm and the welding torch to the target position. Subsequently, the robotic arm drives the welding torch to weld the reinforcing ring onto the inner wall of the tank assembly.

[0011] As a further improvement to the above technical solution:

[0012] The transverse slide rail is arranged along the length of the transverse arm, and the transverse rack is arranged parallel to the transverse slide rail.

[0013] The structure of a single reinforcing ring clamping mechanism is as follows: it includes a slide base, on the top of which a parallel slide rack and several first slide rails are fitted together. On the top of each first slide rail, several first sliders are fitted together. On the top of each first slider, a slide plate is fitted together. A first motor is fixed on the top of the slide plate. The output end of the first motor passes through the slide plate and is connected to a slide gear located below the slide plate. The slide gear meshes with the slide rack. The first motor drives the slide plate to reciprocate linearly along the first slide rails through the slide gear and slide rack.

[0014] A column is mounted on the top of the slide plate, and an inclined clamping support is mounted on the top of the column. The top surface of the clamping support forms an angle with the horizontal plane. Several parallel second slide rails are mounted on the top surface of the clamping support. Several second sliders are mounted on the top of each second slide rail. A clamping roller mounting frame is mounted on the top of each second slider through a clamping connecting seat. The clamping roller mounting frame is H-shaped and has an inward concave arc. Clamping rollers are mounted on both ends of the clamping roller mounting frame. A second motor is fixed on the top surface of the clamping support, and the output end of the second motor is connected to the clamping lift.

[0015] The output end of the clamping lift is connected to the clamping connecting seat. The second motor drives the clamping connecting seat to reciprocate linearly along the second slide rail through the clamping lift, so that the two clamping rollers are in contact with or away from the outer wall of the tank assembly.

[0016] The driven end roller frame mechanism has the following structure: it includes a first base, a first connecting plate is installed on the top of the first base, and symmetrically arranged first mounting seats are installed on the top of the first connecting plate. A driven roller is rotatably installed in a single first mounting seat.

[0017] The active end roller frame mechanism has the following structure: it includes a second base, on the top of which are symmetrically arranged roller lifters. The tops of the two roller lifters are simultaneously mounted with second connecting plates. A steering gear is mounted on the second base between the two roller lifters. Each roller lifter is connected to the output end of the steering gear via a connecting shaft. A lifting motor is fixed on the second base. The output end of the lifting motor is connected to the steering gear. The lifting motor drives the two connecting shafts to rotate simultaneously via the steering gear, thereby driving the corresponding roller lifter to simultaneously move the second connecting plate in a straight line along the vertical direction.

[0018] The top of the second connecting plate is fitted with symmetrically arranged second mounting seats. A drive roller is rotatably installed inside a single second mounting seat. A drive motor is fixed to the outside of a single second mounting seat. The output end of the drive motor is connected to the drive roller. The drive motor drives the drive roller to rotate, thereby causing the tank assembly placed on the support unit to rotate.

[0019] A third mounting base is fixed on the second connecting plate between the two second mounting bases. A symmetrically arranged drive cylinder is fixed on the third mounting base. The output end of a single drive cylinder is connected to the middle of the connecting frame. Both connecting frames are H-shaped and symmetrically arranged. One end of a single connecting frame is rotatably connected to the third mounting base, while the other end is fitted with a conductive block. The conductive block is connected to an external power source through a terminal block. When the drive cylinder extends, it drives the corresponding conductive block to contact the outer wall of the tank assembly through the corresponding connecting frame. When the drive cylinder retracts, it drives the corresponding conductive block to leave the outer wall of the tank assembly through the corresponding connecting frame.

[0020] The support unit also includes a lifting mechanism installed between the driven end roller frame mechanism and the active end roller frame mechanism. The lifting mechanism has the following structure: it includes a lifting base, a lifting motor is fixed on the lifting base, a lifting jack is installed in the middle of the lifting base, the lifting jack is connected to the output end of the lifting motor, the output end of the lifting jack is connected to the lifting pad, and the lifting motor drives the lifting pad to move in a straight line, either upward or downward, in the vertical direction through the lifting jack.

[0021] Several lifting guide shafts are installed on the lifting base. The lifting guide shafts are symmetrically arranged on both sides of the lifting machine, and the top of each lifting guide shaft is connected to the bottom of the lifting pad.

[0022] The welding station is also equipped with a dust removal mechanism. The structure of the dust removal mechanism includes a dust suction hood installed next to the welding torch and a dust removal device installed on the top of the rotating connecting seat. The output end of the dust removal device is connected to the dust suction hood through a hose. The dust removal device uses the dust suction hood to absorb the fumes generated during the welding process.

[0023] The top of the horizontal moving arm is also equipped with a welding machine, a wire feeder, and a control cabinet. The welding machine and the wire feeder provide welding wire for the welding gun.

[0024] A gun cleaner corresponding to the welding gun is installed on the rotating connecting seat, and a counterweight is installed on the horizontal section of the rotating connecting seat.

[0025] The clamping support station also includes a manual platform.

[0026] The beneficial effects of this invention are as follows:

[0027] This invention features a compact and reasonable structure and is easy to operate. By providing an automatic welding device for assembling reinforcing rings for aluminum alloy powder tank trucks, it can automatically weld the reinforcing rings to the tank body sub-assemblies. The high degree of automation can shorten the processing time and thus improve production efficiency. At the same time, the automated production method can effectively reduce the intensity of manual labor and ensure production safety.

[0028] (1) In this invention, the tank sub-assembly is shaped by setting a reinforcing ring clamping mechanism. By setting a clamping support with an inclined surface, a clamping roller mounting frame with an arc concave shape, and symmetrically arranged clamping rollers, the deformation of the tank sub-assembly caused by its own insufficient rigidity can be eliminated, and the tank sub-assembly can be kept in its original shape. This facilitates the matching and installation of the reinforcing ring and the tank sub-assembly, and effectively improves production efficiency.

[0029] (2) In this invention, by setting an active end roller frame mechanism, while supporting the tank sub-assembly, the active end roller frame mechanism has a lifting function, which can make corresponding rising or falling movements in accordance with the shape of the tank sub-assembly during its rotation, so that the tank sub-assembly is always in a horizontal state and the welding accuracy is guaranteed.

[0030] (3) In this invention, by setting up a lifting mechanism, when a gap appears between the reinforcing ring and the tank assembly, the tank assembly is lifted up so that the reinforcing ring fits into the tank assembly, thereby reducing or eliminating the gap between the two, improving processing accuracy, and ensuring processing quality.

[0031] (4) In this invention, by setting a rotary motor, a slewing bearing, a connecting seat, and a counterweight, the welding station has a rotation function, so that after the automatic welding device finishes welding the workpiece on one side of the support station, it can rotate 180° to start welding the workpiece on the other side of the support station, thus ensuring production continuity and improving production efficiency.

[0032] (5) In this invention, by setting a transverse motor, transverse slide rail, transverse slider, transverse rack and transverse gear, the transverse arm can move in a straight line along the transverse slide rail, and the welding gun is driven by the mechanical arm to move in a straight line, so as to weld the reinforcing rings at different positions inside a tank assembly, and ensure the welding quality.

[0033] (6) By setting up a dust removal mechanism, the present invention can adsorb the fumes generated during the welding process of the welding torch, ensuring that the production process is environmentally friendly and clean; at the same time, in conjunction with the torch cleaner, it can effectively prevent foreign objects from clogging the welding torch during the welding process, ensuring the working stability of the automatic welding device.

[0034] (7) By setting up various sensor components, the welding accuracy can be effectively improved and the production quality and product consistency can be guaranteed.

[0035] (8) The present invention has a compact layout, occupies a small area, and does not require a high installation site, thereby improving the flexibility of use; at the same time, the automatic welding device in the present invention can save a clamping support station, thereby further reducing the installation area and meeting the needs of small factories. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the structure of the present invention.

[0037] Figure 2 for Figure 1 Top view.

[0038] Figure 3 This is a schematic diagram of the welding station in this invention.

[0039] Figure 4 for Figure 3 A magnified view of a portion of point A in the middle.

[0040] Figure 5 for Figure 3 The main view.

[0041] Figure 6 This is a schematic diagram of the reinforcing ring clamping mechanism in this invention.

[0042] Figure 7 for Figure 6 The main view.

[0043] Figure 8This is a schematic diagram of the driven end roller frame mechanism in this invention.

[0044] Figure 9 This is a schematic diagram of the active end roller frame mechanism in this invention.

[0045] Figure 10 for Figure 9 Exploded view.

[0046] Figure 11 for Figure 9 The main view.

[0047] Figure 12 for Figure 9 Rear view.

[0048] Figure 13 This is a schematic diagram of the lifting mechanism in this invention.

[0049] Figure 14 for Figure 13 The main view.

[0050] Figure 15 This is a schematic diagram of the installation structure of the tank body sub-assembly and the reinforcing ring in this invention.

[0051] Figure 16 This is a schematic diagram of the present invention in operation.

[0052] The components include: 1. Reinforcing ring clamping mechanism; 2. Driven end roller frame mechanism; 3. Driving end roller frame mechanism; 4. Lifting mechanism; 5. Manual platform; 6. Welding torch; 7. Robotic arm; 8. Base; 9. Rotary connecting seat; 10. Lateral arm; 11. Rotary motor; 12. Slewing bearing; 13. Lateral slide rail; 14. Lateral slider; 15. Lateral motor; 16. Lateral gear; 17. Lateral rack; 18. Welding machine; 19. Wire feeder; 20. Torch cleaner; 21. Dust removal mechanism; 22. Tank sub-assembly; 23. Reinforcing ring; 24. Counterweight.

[0053] 101. Slide base; 102. First slide rail; 103. First slider; 104. Slide gear; 105. Slide rack; 106. First motor; 107. Slide plate; 108. Column; 109. Clamping support; 110. Second slide rail; 111. Second slider; 112. Second motor; 113. Clamping lift; 114. Clamping roller mounting bracket; 115. Clamping roller; 116. Clamping connecting seat;

[0054] 201. First base; 202. First connecting plate; 203. First mounting seat; 204. Driven roller;

[0055] 301. Second base; 302. Second connecting plate; 303. Lifting motor; 304. Steering gear; 305. Connecting shaft; 306. Roller lift; 307. Roller drive motor; 308. Drive roller; 309. Second mounting base; 310. Third mounting base; 311. Drive cylinder; 312. Connecting frame; 313. Conductive block;

[0056] 401. Lifting base; 402. Lifting motor; 403. Lifting jack; 404. Lifting guide shaft; 405. Bushing; 406. Lifting pad;

[0057] 2101. Dust hood; 2102. Dust removal equipment. Detailed Implementation

[0058] The specific embodiments of the present invention will now be described with reference to the accompanying drawings.

[0059] The structure and function of this invention are as follows:

[0060] like Figures 1-16As shown, an automatic welding device for reinforcing ring assemblies of an aluminum alloy powder tank truck includes a welding station. Symmetrically arranged clamping support stations are installed on both sides of the welding station. Each clamping support station includes a clamping unit and a support unit installed in the middle of the clamping unit. The support unit includes a driven end roller frame mechanism 2 and an active end roller frame mechanism 3. The tops of the driven end roller frame mechanism 2 and the active end roller frame mechanism 3 simultaneously support the tank body sub-assembly 22. A lifting motor 303 and a roller drive motor 307 are installed on the active end roller frame mechanism 3. The lifting motor 303 drives the active end roller frame mechanism 3 along... The vertical movement upwards or downwards is used to level the tank sub-assembly 22. The roller drive motor 307 drives the active end roller frame mechanism 3 to rotate the tank sub-assembly 22. The clamping unit includes reinforcing ring clamping mechanisms 1 symmetrically arranged on both sides of the tank sub-assembly 22. When the welding station is working, the two reinforcing ring clamping mechanisms 1 simultaneously hold the outer side wall of the tank sub-assembly 22, thereby correcting the shape of the tank sub-assembly 22. The structure of the welding station includes a base 8, on which a rotary motor 11 is fixed. The output end of the rotary motor 11 is connected to a rotary gear, which meshes with the inner ring of the rotary bearing 12. The top of the base 8 is mounted to an L-shaped rotary connecting seat 9 via a slewing bearing 12. A rotary motor 11 drives the rotary connecting seat 9 to rotate via the slewing bearing 12. A transverse arm 10 is mounted on the top of the vertical section of the rotary connecting seat 9. A robotic arm 7 is mounted on one end of the transverse arm 10, and a welding torch 6 is mounted on the working end of the robotic arm 7. A transverse rack 17 is mounted on one side of the transverse arm 10. Several parallel transverse slide rails 13 are mounted on the bottom of the transverse arm 10. Each transverse slide rail 13 is mounted with several transverse sliders 14. The transverse sliders 14 are mounted on the rotary connecting seat. At the top of the vertical section of the connecting seat 9, a transverse motor 15 is fixed on the vertical section of the rotating connecting seat 9. The output end of the transverse motor 15 is connected to the transverse gear 16. The transverse gear 16 meshes with the transverse rack 17. The transverse motor 15 drives the transverse arm 10 to reciprocate linearly along the transverse slide rail 13 through the transverse gear 16 and the transverse rack 17, thereby driving the robotic arm 7 and the welding torch 6 to reach the target position. Then, the robotic arm 7 drives the welding torch 6 to weld the reinforcing ring 23 onto the inner wall of the tank sub-assembly 22. The transverse slide rail 13 is arranged along the length of the transverse arm 10, and the transverse rack 17 is arranged parallel to the transverse slide rail 13. The welding station is used to weld the tank sub-assembly 22 and the reinforcing ring 23; the reinforcing ring clamping mechanism 1 is used to straighten the tank sub-assembly 22 without the reinforcing ring 23 to prevent deformation and improve the installation accuracy of the reinforcing ring 23; the active end roller frame mechanism 3 is used to drive the tank sub-assembly 22 to rotate to change the welding angle, and the driven end roller frame mechanism 2 is used to assist in supporting the tank sub-assembly 22.

[0061] Two reinforcing rings 23 need to be installed inside the tank sub-assembly 22. The welding torch 6 moves horizontally in a straight line via the transverse arm 10, thereby achieving two different welding positions.

[0062] The automatic welding device is equipped with two clamping support stations. When the tank sub-assembly 22 and reinforcing ring 23 on the left clamping support station are automatically welded by the welding gun 6, the right clamping support station loads the parts. When the tank sub-assembly 22 and reinforcing ring 23 on the left clamping support station are welded, the welding gun 6 rotates to the right side through the rotating connecting seat 9 and welds the workpiece on that side. At this time, the left clamping support station unloads the parts and enters the next work cycle. This can effectively save loading and unloading time, shorten processing time, and improve processing efficiency.

[0063] In this invention, the rotating connecting seat 9 can drive the welding torch 6 to rotate around its rotation center at any angle. Therefore, the two clamping support stations are not limited to a symmetrical arrangement, and the number of clamping support stations is not limited to two. Multiple clamping support stations can be arranged arbitrarily along the circumference outside the welding station.

[0064] A laser tracking sensor is installed on one side of the welding torch 6. Using laser tracking technology, the laser tracking sensor guides the robotic arm 7 to move during the welding process of the welding torch 6, ensuring processing accuracy and quality.

[0065] The structure of the single reinforcing ring clamping mechanism 1 is as follows: It includes a slide base 101, on the top of which are mounted parallel slide racks 105 and several first slide rails 102. Several first sliders 103 are mounted on the top of each first slide rail 102. A slide plate 107 is mounted on the top of each first slider 103. A first motor 106 is fixed to the top of the slide plate 107. The output end of the first motor 106 passes through the slide plate 107 and connects to a slide gear 104 located below the slide plate 107. The slide gear 104 meshes with the slide rack 105. The first motor 106 drives the slide plate 107 to reciprocate linearly along the first slide rails 102 via the slide gear 104 and slide rack 105. A column 108 is mounted on the top of the slide plate 107, and an inclined clamping support 109 is mounted on the top of the column 108. The top of the clamping support 109... The surface forms an angle with the horizontal plane. Several parallel second slide rails 110 are installed on the top surface of the clamping support 109. Several second sliders 111 are installed on the top of each second slide rail 110. The top of the second sliders 111 is fitted with a clamping roller mounting bracket 114 through a clamping connecting seat 116. The clamping roller mounting bracket 114 is H-shaped and has an inward concave arc. Clamping rollers 115 are installed at both ends of the clamping roller mounting bracket 114. A second motor 112 is fixed on the top surface of the clamping support 109. The output end of the second motor 112 is connected to the clamping lift 113. The output end of the clamping lift 113 is connected to the clamping connecting seat 116. The second motor 112 drives the clamping connecting seat 116 to reciprocate linearly along the second slide rail 110 through the clamping lift 113, so that the two clamping rollers 115 are in contact with or away from the outer wall of the tank sub-assembly 22. The clamping roller 115 is a rubber-coated roller, which can prevent scratches on the surface of the tank assembly 22.

[0066] Before the reinforcing ring 23 is installed, the tank sub-assembly 22 is prone to deformation due to its insufficient rigidity, which may prevent the reinforcing ring 23 from being installed inside it. When the tank sub-assembly 22 deforms, it needs to be lifted manually with the help of an overhead crane to restore it to its original shape, which causes inconvenience to production.

[0067] In this invention, by setting up a reinforcing ring clamping mechanism 1, when welding the reinforcing ring 23, the clamping roller 115 supports and limits the corresponding position of the tank sub-assembly 22, thereby correcting its shape and effectively preventing its deformation, which can effectively speed up the installation speed and ensure processing accuracy.

[0068] During the operation of the automatic welding device, multiple reinforcing rings 23 need to be welded onto a tank sub-assembly 22. The installation positions of the reinforcing rings 23 are different. By setting the first slide rail 102, the first slider 103, the slide gear 104, the slide rack 105, the first motor 106, and the slide plate 107, the reinforcing ring clamping mechanism 1 can move accordingly with the installation position of the reinforcing rings 23 to adapt to the installation of different reinforcing rings 23.

[0069] The driven end roller frame mechanism 2 has the following structure: it includes a first base 201, a first connecting plate 202 is mounted on the top of the first base 201, and symmetrically arranged first mounting seats 203 are mounted on the top of the first connecting plate 202. A driven roller 204 is rotatably mounted in each of the first mounting seats 203. The driven end roller frame mechanism 2 is used to cooperate with the active end roller frame mechanism 3 to support the tank sub-assembly 22. At the same time, in order to ensure welding quality, the tank sub-assembly 22 needs to be in different welding positions during the welding process. The active end roller frame mechanism 3 can drive the tank sub-assembly 22 to rotate. During the rotation of the tank sub-assembly 22, the driven end roller frame mechanism 2 plays an auxiliary role in the rotation. The welding torch 6 can complete the welding without making large movements, thereby effectively improving the processing accuracy.

[0070] The active end roller frame mechanism 3 has the following structure: It includes a second base 301, on the top of which are symmetrically arranged roller lifters 306. A second connecting plate 302 is mounted on the top of both roller lifters 306. A steering mechanism 304 is mounted on the second base 301 between the two roller lifters 306. Each roller lifter 306 is connected to the output end of the steering mechanism 304 via a connecting shaft 305. A lifting motor 303 is fixed on the second base 301, and its output end is connected to the steering mechanism 304. The lifting motor 303 drives both connecting shafts 305 to rotate simultaneously via the steering mechanism 304, thereby driving the corresponding roller lifter 306 to simultaneously move the second connecting plate 302 in a vertical linear motion. Symmetrically arranged second mounting seats 309 are mounted on the top of the second connecting plate 302. An active roller 308 is rotatably mounted inside each second mounting seat 309, and a roller drive motor 307 is fixed to the outside of each second mounting seat 309. The output end of the roller drive motor 307 is connected to the active roller 308. The roller drive motor 307 drives the active roller 308 to rotate, thereby driving the tank sub-assembly 22 placed on the support unit to rotate. A third mounting base 310 is fixed on the second connecting plate 302 between the two second mounting bases 309. A symmetrically arranged drive cylinder 311 is fixed on the third mounting base 310. The output end of a single drive cylinder 311 is connected to the middle of the connecting frame 312. Both connecting frames 312 are H-shaped and symmetrically arranged. One end of a single connecting frame 312 is rotatably connected to the third mounting base 310, while the other end is fitted with a conductive block 313. The conductive block 313 is connected to an external power supply through a terminal block. When the drive cylinder 311 extends, it drives the corresponding conductive block 313 to contact the outer wall of the tank sub-assembly 22 through the corresponding connecting frame 312. When the drive cylinder 311 retracts, it drives the corresponding conductive block 313 to leave the outer wall of the tank sub-assembly 22 through the corresponding connecting frame 312. The active end roller frame mechanism 3 has active rotation and lifting functions.

[0071] Since the tank assembly 22 is an irregular tank, it will tilt during its rotation. In order to level the tank assembly 22, the active end roller frame mechanism 3 has a lifting function. Through the steering gear 304 and the two connecting shafts 305, the driving force output by the lifting motor 303 is transmitted to the two roller lifting machines 306 respectively, thereby driving the second connecting plate 302 to rise or fall in the vertical direction, so that the tank assembly 22 always remains horizontal.

[0072] The active end roller frame mechanism 3 is equipped with a detection component, including a friction wheel and an encoder, for detecting and tracking the rotational position of the tank sub-assembly 22. After the tank sub-assembly 22 is placed on the support unit, the friction wheel is always in contact with the tank sub-assembly 22. The rotation of the tank sub-assembly 22 drives the friction wheel to rotate. The linear velocity of the tank sub-assembly 22 and the friction wheel are always consistent. By using the encoder technology driven by the rotation of the friction wheel, the rotational position of the tank sub-assembly 22 is automatically calculated and obtained, so that the automatic welding device can complete fully automatic welding without manual intervention, thereby improving the automation level of the device.

[0073] The conductive block 313 is connected to an external power source, and a ground wire is installed on the third mounting base 310 to ensure safety. When the tank sub-assembly 22 needs to rotate, the drive cylinder 311 retracts, causing the conductive block 313 to move away from the outer wall of the tank sub-assembly 22, preventing the conductive block 313 from rubbing against the outer wall of the tank sub-assembly 22 during rotation. When the tank sub-assembly 22 is rotated to the correct position, the drive cylinder 311 extends, causing the conductive block 313 to fit against the outer wall of the tank sub-assembly 22. The drive cylinder 311 is equipped with a magnetic switch that can detect whether the drive cylinder 311 has extended to the correct position. When the magnetic switch detects that the drive cylinder 311 has extended to the correct position, the welding conditions of the welding torch 6 are met, and the welding torch 6 performs welding under the drive of the robotic arm 7.

[0074] A symmetrically arranged lifting guide shaft assembly is installed between the second connecting plate 302 and the second base 301. Each lifting guide shaft assembly includes lifting guide shafts symmetrically arranged on both sides of a single roller lift 306. When the roller lift 306 drives the second connecting plate 302 to move up and down, the lifting guide shafts are used to stabilize the movement of the second connecting plate 302, and the lifting guide shaft assembly is used as a guide for the lifting of the second connecting plate 302.

[0075] The support unit also includes a lifting mechanism 4 installed between the driven end roller frame mechanism 2 and the active end roller frame mechanism 3. The lifting mechanism 4 has the following structure: it includes a lifting base 401, a lifting motor 402 fixed on the lifting base 401, a lifting jack 403 installed in the middle of the lifting base 401, the lifting jack 403 connected to the output end of the lifting motor 402, and the output end of the lifting jack 403 connected to the lifting pad 406. The lifting motor 402 drives the lifting pad 406 to move vertically upward or downward through the lifting jack 403. Several lifting guide shafts 404 are installed on the lifting base 401. The lifting guide shafts 404 are symmetrically arranged on both sides of the lifting jack 403, and the top of each lifting guide shaft 404 is connected to the bottom of the lifting pad 406. Due to processing errors, a gap may occur between the reinforcing ring 23 and the inner wall of the tank sub-assembly 22. The lifting mechanism 4 enables the reinforcing ring 23 to fit better with the tank sub-assembly 22. The lifting motor 402 drives the lifting machine 403 to raise the lifting pad 406 vertically, thereby lifting the tank sub-assembly 22 and making the inner wall of the tank sub-assembly 22 fit with the reinforcing ring 23 to reduce the gap and facilitate subsequent welding work by the welding torch 6. The single lifting guide shaft 404 is installed in conjunction with the lifting base 401 through the bushing 405. The lifting guide shaft 404 and the bushing 405 have the functions of guiding and stabilizing the movement of the lifting pad 406.

[0076] A dust removal mechanism 21 is also installed at the welding station. The structure of the dust removal mechanism 21 includes a dust suction hood 2101 installed alongside the welding torch 6, and a dust removal device 2102 installed on top of the rotating connecting seat 9. The output end of the dust removal device 2102 is connected to the dust suction hood 2101 via a flexible hose. The dust removal device 2102 uses the dust suction hood 2101 to absorb the fumes generated during the welding process of the welding torch 6. A dust suction hood is installed at the front end of the welding torch, and the dust suction hood and the dust extraction device are connected via a flexible hose. When the robot is welding, the dust extraction device is activated, and the welding fumes enter the dust suction hood and are then sent through the hose to the dust removal device for filtration and discharge. The welding fume capture method adopts a high negative pressure dust collection method. This typically utilizes the high negative pressure inherent in the equipment itself to overcome the pressure loss of the capture element, using a high-speed airflow to capture the welding fumes generated near the capture element. This design does not affect the robot's welding posture and effectively absorbs the welding fumes.

[0077] The top of the horizontal moving arm 10 is also equipped with a welding machine 18, a wire feeder 19, and a control cabinet. The welding machine 18 and the wire feeder 19 provide welding wire to the welding torch 6. The welding machine 18 and the wire feeder 19 work together to enable the welding torch 6 to produce molten welding wire to connect the reinforcing ring 23 to the tank sub-assembly 22; the control cabinet is used to control the movement of the robotic arm 7.

[0078] A cleaning device 20 corresponding to the welding torch 6 is installed on the rotating connecting seat 9, and a counterweight 24 is installed on the horizontal section of the rotating connecting seat 9. The cleaning device 20 is used to clean the sticky material inside the welding torch 6 during the welding process to ensure the working stability of the welding torch 6; the counterweight 24 is used to keep the rotating connecting seat 9 balanced to ensure the working stability of the automatic welding device.

[0079] The support station also includes a manual platform 5. The manual platform 5 is used to facilitate operators to enter the tank sub-assembly 22 to spot weld and install the reinforcing ring 23.

[0080] The working process of this invention is as follows:

[0081] The tank assembly 22 is transported to a clamping support station, so that the tank assembly 22 is placed on top of both the active end roller frame mechanism 3 and the driven end roller frame mechanism 2.

[0082] The operator checks the status of the tank sub-assembly 22, fine-tunes its position, and after confirming that the status of the tank sub-assembly 22 is correct, simultaneously starts the two first motors 106 of the corresponding clamping unit, drives the corresponding slide gear 104 to rotate, drives the corresponding slide plate 107 to move linearly along the corresponding first slide rail 102, thereby moving the two corresponding clamping rollers 115 into position. Then, the two second motors 112 of the corresponding clamping unit are started, drives the corresponding clamping lift 113 to move linearly, thereby moving the two corresponding clamping rollers 115 forward. The two reinforcing ring clamping mechanisms 1 simultaneously fit against the outer wall of the tank sub-assembly 22, so that the clamping unit clamps the tank sub-assembly 22.

[0083] During the operation of the clamping unit, the tank sub-assembly 22 remains stationary;

[0084] The two reinforcing rings 23 are moved into the tank sub-assembly 22, and the operators weld the two reinforcing rings 23 to fix them in place, so that the two reinforcing rings 23 are initially positioned.

[0085] After manual tack fixing, the installation position of the reinforcing ring 23 was checked and confirmed to be correct. Then, the two reinforcing rings 23 were fully welded by the welding station.

[0086] Start the rotary motor 11, which drives the rotary connecting seat 9 to rotate through the rotary gear and rotary bearing 12, thereby rotating the welding torch 6 into position;

[0087] Then, the transverse motor 15 is started, driving the transverse gear 16 to rotate, which in turn drives the transverse arm 10 to move linearly along the transverse slide rail 13, thereby allowing the welding torch 6 to extend into the interior of the tank sub-assembly 22 and reach the welding position of the corresponding reinforcing ring 23.

[0088] Subsequently, the roller drive motor 307 on the clamping support station starts, driving the active roller 308 to rotate, thereby driving the tank sub-assembly 22 to rotate. During the rotation of the tank sub-assembly 22, the welding gun 6 welds the circumferential seam between the reinforcing ring 23 and the tank sub-assembly 22.

[0089] During the rotation of the tank sub-assembly 22, due to the irregular shape of the tank sub-assembly 22, the lifting motor 303 provides driving force to the two roller lifting machines 306 through the steering gear 304 and two connecting shafts 305 according to the rotation position of the tank sub-assembly 22, thereby driving the active roller 308 to rise or fall in the vertical direction, so that the tank sub-assembly 22 always remains horizontal during the rotation to ensure welding accuracy;

[0090] During the welding process of the welding torch 6 on the tank sub-assembly 22, the drive cylinder 311 is always extended, so that the conductive block 313 is in contact with the outer wall of the tank sub-assembly 22; when the tank sub-assembly 22 completes the welding of one welding position and needs to be rotated to the next welding position, the drive cylinder 311 retracts, so that the conductive block 313 leaves the outer wall of the tank sub-assembly 22, preventing the conductive block 313 from scratching the tank sub-assembly 22.

[0091] When the robotic arm 7 drives the welding torch 6 to perform welding work, the welding torch 6 performs intermittent welding 200 on the welding position, which consists of 36 weld seams and 32 weld seams. During the welding process, the tank sub-assembly 22 needs to be rotated at different angles twice.

[0092] After welding is completed, the part is removed and the next work cycle begins;

[0093] When the automatic welding device is working, manual labor and robots take turns working at two clamping support stations.

[0094] This invention provides an automatic welding device for reinforcing ring assembly of aluminum alloy powder tank trucks. It adopts automated equipment to replace the traditional manual processing and production method, reducing the intensity of manual labor and the dependence on welding workers. The dual-station alternating operation improves production efficiency. By setting up detection components and sensor components, the quality of the weld can be monitored, which can improve processing accuracy and ensure product quality.

[0095] The above description is an explanation of the present invention and not a limitation thereof. The scope of the present invention is defined by the claims. Within the scope of protection of the present invention, any form of modification may be made.

Claims

1. An apparatus for automatic welding of a set of aluminum alloy powder tank car reinforcing rings, characterized by: The system includes a welding station, on both sides of which are symmetrically arranged clamping support stations. Each clamping support station includes a clamping unit and a support unit installed in the middle of the clamping unit. The support unit includes a driven end roller frame mechanism (2) and an active end roller frame mechanism (3). The tops of the driven end roller frame mechanism (2) and the active end roller frame mechanism (3) simultaneously support the tank sub-assembly (22). The active end roller frame mechanism (3) is equipped with a lifting motor (303) and a roller drive motor (307). The lifting motor (303) drives the active end roller frame mechanism (3) to move vertically upward or downward in a straight line to level with the tank sub-assembly (22). The roller drive motor (307) drives the active end roller frame mechanism (3) to rotate the tank sub-assembly (22). The clamping unit includes reinforcing ring clamping mechanisms (1) symmetrically arranged on both sides of the tank sub-assembly (22). When the welding station is working, the two reinforcing ring clamping mechanisms (1) simultaneously hold the outer side wall of the tank sub-assembly (22) to correct the shape of the tank sub-assembly (22). The structure of the welding station is as follows: it includes a base (8), on which a rotary motor (11) is fixed. The output end of the rotary motor (11) is connected to a rotary gear. The rotary gear meshes with the inner ring of a rotary bearing (12). The top of the base (8) is installed with an L-shaped rotary connecting seat (9) through the rotary bearing (12). The rotary motor (11) drives the rotary connecting seat (9) to rotate through the rotary bearing (12). A transverse arm (10) is fitted at the top of the vertical section of the rotating connecting seat (9). A robotic arm (7) is fitted at one end of the transverse arm (10). A welding torch (6) is fitted at the working end of the robotic arm (7). A transverse rack (17) is fitted on one side of the transverse arm (10). Several parallel transverse slide rails (13) are fitted at the bottom of the transverse arm (10). Each transverse slide rail (13) is fitted with several transverse sliders (14). The transverse sliders (14) are installed at the top of the vertical section of the rotating connecting seat (9). A transverse motor (15) is fixed on the vertical section of the connecting seat (9). The output end of the transverse motor (15) is connected to a transverse gear (16). The transverse gear (16) meshes with a transverse rack (17). The transverse motor (15) drives the transverse arm (10) to reciprocate linearly along the transverse slide rail (13) through the transverse gear (16) and the transverse rack (17), thereby driving the robotic arm (7) and the welding torch (6) to reach the target position. Then, the robotic arm (7) drives the welding torch (6) to weld the reinforcing ring (23) onto the inner wall of the tank sub-assembly (22).

2. The apparatus of claim 1 wherein: The transverse slide rail (13) is arranged along the length of the transverse arm (10), and the transverse rack (17) is arranged parallel to the transverse slide rail (13).

3. The apparatus of claim 1 wherein: The structure of the single reinforcing ring clamping mechanism (1) is as follows: it includes a slide base (101), on the top of the slide base (101) are a parallel slide rack (105) and several first slide rails (102), on the top of each first slide rail (102) are several first sliders (103), on the top of each first slider (103) are a slide plate (107), on the top of the slide plate (107) is a first motor (106), the output end of the first motor (106) passes through the slide plate (107) and is connected to the slide gear (104) located below the slide plate (107), the slide gear (104) meshes with the slide rack (105), and the first motor (106) drives the slide plate (107) to reciprocate linearly along the first slide rail (102) through the slide gear (104) and the slide rack (105); A column (108) is fitted onto the top of the slide plate (107), and an inclined clamping support (109) is fitted onto the top of the column (108). The top surface of the clamping support (109) forms an angle with the horizontal plane. Several parallel second slide rails (110) are fitted onto the top surface of the clamping support (109), and several second sliders (111) are fitted onto the top of each second slide rail (110). The top of the slider (111) is fitted with a clamping roller mounting bracket (114) through a clamping connecting seat (116). The clamping roller mounting bracket (114) is H-shaped and has an inward concave arc. The two ends of the clamping roller mounting bracket (114) are fitted with clamping rollers (115). The top surface of the clamping support (109) is fixed with a second motor (112). The output end of the second motor (112) is connected to the clamping lift (113). The output end of the clamping lift (113) is connected to the clamping connecting seat (116). The second motor (112) drives the clamping connecting seat (116) to reciprocate linearly along the second slide rail (110) through the clamping lift (113), so that the two clamping rollers (115) are in contact with or away from the outer wall of the tank sub-assembly (22).

4. The apparatus of claim 1 wherein: The structure of the driven end roller frame mechanism (2) is as follows: it includes a first base (201), a first connecting plate (202) is installed on the top of the first base (201), and a first mounting seat (203) is symmetrically arranged on the top of the first connecting plate (202). A driven roller (204) is rotatably installed in a single first mounting seat (203).

5. The apparatus of claim 1 wherein: The active end roller frame mechanism (3) has the following structure: it includes a second base (301), and symmetrically arranged roller lifters (306) are installed on the top of the second base (301). The tops of the two roller lifters (306) are simultaneously installed with a second connecting plate (302). A steering gear (304) is installed on the second base (301) between the two roller lifters (306). A single roller lifter (306) is connected to the output end of the steering gear (304) through a connecting shaft (305). A lifting motor (303) is fixed on the second base (301). The output end of the lifting motor (303) is connected to the steering gear (304). The lifting motor (303) drives the two connecting shafts (305) to rotate simultaneously through the steering gear (304), thereby driving the corresponding roller lifter (306) to simultaneously drive the second connecting plate (302) to move in a straight line in the vertical direction. The top of the second connecting plate (302) is fitted with symmetrically arranged second mounting seats (309). A drive roller (308) is rotatably mounted inside a single second mounting seat (309). A roller drive motor (307) is fixed outside the single second mounting seat (309). The output end of the roller drive motor (307) is connected to the drive roller (308). The roller drive motor (307) drives the drive roller (308) to rotate, thereby driving the tank sub-assembly (22) placed on the support unit to rotate. A third mounting base (310) is fixed on a second connecting plate (302) between two second mounting bases (309). A symmetrically arranged drive cylinder (311) is fixed on the third mounting base (310). The output end of a single drive cylinder (311) is connected to the middle of a connecting frame (312). Both connecting frames (312) are H-shaped and symmetrically arranged. One end of a single connecting frame (312) is rotatably connected to the third mounting base (310), while the other end is fitted with a conductive block (313). The conductive block (313) is connected to an external power source through a terminal block. When the drive cylinder (311) extends, it drives the corresponding conductive block (313) to contact the outer wall of the tank sub-assembly (22) through the corresponding connecting frame (312). When the drive cylinder (311) retracts, it drives the corresponding conductive block (313) to leave the outer wall of the tank sub-assembly (22) through the corresponding connecting frame (312).

6. The automatic welding device for reinforcing ring assembly of aluminum alloy powder tank truck as described in claim 1, characterized in that: The support unit also includes a lifting mechanism (4) installed between the driven end roller frame mechanism (2) and the active end roller frame mechanism (3). The structure of the lifting mechanism (4) is as follows: it includes a lifting base (401), a lifting motor (402) is fixed on the lifting base (401), a lifting jack (403) is installed in the middle of the lifting base (401), the lifting jack (403) is connected to the output end of the lifting motor (402), the output end of the lifting jack (403) is connected to the lifting pad (406), and the lifting motor (402) drives the lifting pad (406) to make a linear motion of rising or falling in the vertical direction through the lifting jack (403). Several lifting guide shafts (404) are installed on the lifting base (401). The lifting guide shafts (404) are symmetrically arranged on both sides of the lifting machine (403). The top of a single lifting guide shaft (404) is connected to the bottom of the lifting pad (406).

7. The automatic welding device for reinforcing ring assembly of aluminum alloy powder tank truck as described in claim 1, characterized in that: The welding station is also equipped with a dust removal mechanism (21). The structure of the dust removal mechanism (21) is as follows: it includes a dust suction hood (2101) installed next to the welding gun (6) and a dust removal device (2102) installed on the top of the rotating connecting seat (9). The output end of the dust removal device (2102) is connected to the dust suction hood (2101) through a hose. The dust removal device (2102) adsorbs the fumes generated during the welding process of the welding gun (6) through the dust suction hood (2101).

8. The automatic welding device for reinforcing ring assembly of aluminum alloy powder tank truck as described in claim 1, characterized in that: The top of the transverse arm (10) is also equipped with a welding machine (18), a wire feeder (19) and a control cabinet. The welding machine (18) and the wire feeder (19) provide welding wire to the welding gun (6).

9. The automatic welding device for reinforcing ring assembly of aluminum alloy powder tank truck as described in claim 1, characterized in that: A cleaning device (20) corresponding to the welding torch (6) is installed on the rotating connecting seat (9), and a counterweight (24) is installed on the horizontal section of the rotating connecting seat (9).

10. The automatic welding device for reinforcing ring assembly of aluminum alloy powder tank truck as described in claim 1, characterized in that: The clamping support station also includes a manual platform (5).

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